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Procedia Engineering 100 (2015) 177 – 186

25th DAAAM International Symposium on Intelligent Manufacturing and Automation, DAAAM 2014

Ecological Sustainability and Waste Paper Recycling


Ivana Bolanca Mirkovic a*, Igor Majnarica, Zdenka Bolanca b
a
University of Zagreb, Faculty of Graphic Arts, Getaldiceva 2, 10000 Zagreb, Croatia
b
Croatian Academy of Engineering, Kaciceva 28, 10000 Zagreb, Croatia

Abstract

In accordance with environmental sustainability and in order to optimize the recycling process of prints from indirect
electrophotography with liquid toner the results of investigating the effects of changes in printing conditions on the
characteristics of recycled fibres is presented. Changing of printing machine conditions, respecting of voltage variations,
comprises of the reverse rollers and intermediate cylinder.
Based on the results it can be concluded that the change in the voltage of the reverse rollers more affect the recycling efficiency
with respect to the voltage change of the intermediate cylinder. Brightness gain is higher when the print for recycling is made on
uncoated paper compared to coated, and dependent on the voltage changes. Effective residual ink concentration decreases far
more on handsheets obtained from recycled samples on uncoated paper in relation to both sides coated paper. Increasing the
positive voltage of intermediate cylinder and increasing the negative charge of reverse rollers increases the 3 D gamut CIE
L*a*b* color cubic units. Guidelines for the size of the voltage in order to obtain optimal print reproduction are provided.
The further research will include the development in area of clean technologies, advanced materials, closed loop systems;
therefore the significant terms in the area of environmental sustainability.
©2015
© 2015TheThe Authors.
Authors. Published
Published by Elsevier
by Elsevier Ltd.
Ltd. This is an open access article under the CC BY-NC-ND license
Peer-review under responsibility of DAAAM International Vienna.
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of DAAAM International Vienna
Keywords: Electrophotography; Liquid toner; Reverse rollers; Intermediate cylinder; Recycling

1. Introduction

Environmentally more sustainable product system and demands of sustainable conditions will result in
production and consumption that are in the system of contemporarily industrial society and sustainability. The term
of sustainability is significant for the development, and it includes energy and material flows, closed loop systems,

* Corresponding author. Tel.:+ 385 1 2371 080; fax: + 385 1 2371 080.
E-mail address: ivana.bolanca@grf.hr

1877-7058 © 2015 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of DAAAM International Vienna
doi:10.1016/j.proeng.2015.01.356
178 Ivana Bolanca Mirkovic et al. / Procedia Engineering 100 (2015) 177 – 186

clean technologies, economic and social factors, implementation of society values and qualityሾͳሿ.
The waste and the influence on environment depend on the printing technique and the used materials.
Significance of making the right choice is in the field of printing substrates (substrates with high content of
secondary raw material, substrates made from total chlorine-free process), inks (lower solvent content level
biodegradable inks, formulation with more renewable raw material), printing (clean technologies, preparation of
printing forms with no wastewater which contains chemicals from the process, cleaning agents for machine elements
which are based on renewable resource) and post-press finishing, binding process can be specified to enable full
recycling of paper content without glue contamination[2,3].
The digital press based on electrophotography generates less paper and chemical waste than conventional
printing press. Digital electrophotography Indigo press produces paper waste 5-20%, and chemical waste 0.2-1.1g
per impression [4].
Sheet- fed offset press produces 35-75% paper waste and 3.2-7.3g chemical waste per impression [4] The VOC
emission was 74 mg/m3 in the breathing area of digital press and 484 mg/m3 above the conventional press (VOC
emissions expressed as the concentration of n-hexane) [4].Water footprint of the HP Indigo 7000 press option is
59% lower than that of the sheet fed offset press [5].
As the volume of the digitally printed products increases, recyclability of the waste paper becomes important,
because materials can be reused accepting cradle-to-cradle concept [6].
Poorly deinkable digital prints made in the technique of indirect electrophotography with liquid toner ElectroInk
were proved by the investigations [7-9]. ElectroInk appears to produce big specks after pulping, which is difficult to
eliminate in a flotation deinking plant.
The digital printing equipment manufacturers and INGEDE have different opinions on the deinkability of digital
prints. During DRUPA 2008, HP claimed that the version of ElectroInk 4.0 is as deinkable as dry toners. INGEDE
issued a press release starting that the claims were incorrect [10]. Digital printing equipment manufacturers also
question the relevance of the single-step laboratory test of the INGEDE 11 method, claiming that it does not reflect
the industrial conditions of two-loop deinking [11].
The new generation of Electro Ink produces smaller specks after pulping. Specks which are effectively broken
up by dispersion are floatable in a second flotation loop [12, 13].
Zang and co-others describe the design of a laboratory scale two-loop deinking process with inclusion of a low-
speed high shear kneading step in between two flotation steps [14]. The samples for recycling were mixed office
waste and mixtures of mixed office waste with various amounts of liquid electrophotography prints. The two –loop
process successfully brings the dirt area for mixed office waste with liquid electrophotography prints (5% and20%)
to a satisfactory level.
Ng and co-authors demonstrated that good deinkability of HP commercial prints (liquid electrophotography, dry
electrophotography and ink jet) can be achieved with neutral deinking chemistry [15]. They found a direct
correlation of the chemical effects to the ink-particle speck contamination and its particle size distributions.
The aim of our extensive research was to determine the influence of the conditions in indirect electrophotography
with liquid toner (scorotrone voltage, laser strength, voltage of reverse roller, voltage of intermediate cylinder,
concentration of the liquid toner etc.) on effectiveness of the prints recycling [16-19].
In this paper the impact of changes in the voltage of the reverse rollers and voltage variation of intermediate
cylinder in indirect electrophotography with liquid toner on the efficiency of the deinking flotation process is
presented.
The efficiency is determined by the effective residual ink concentration and specks number and area on
handsheets made from pulped and recycled fibers. In order to determine the reproduction quality the same samples
were used, overall extend color information as color 3D gamut and ΔE CIE Lab2000 were investigated.
Research results are the contribution to the explanation of the printing process conditions on prints deinkability,
possibility of the application in the area of reused materials accepting cradle-to-cradle concept and in the design of
graphic products taking into consideration the postulates of ecological sustainable development.

2. Experimental

The samples were made on digital machine Turbo Stream HP Indigo, based on electrophotography. The test form
contained different printing elements: standard CMYK step wedge in the range from 10-100% tone value, standard
ISO illustration and the standard wedge with 378 patches for production of ICC profiles and 3D gamut.
ElectroInk of the third generation and double sided coated paper were used for printing. Paper brightness was
Ivana Bolanca Mirkovic et al. / Procedia Engineering 100 (2015) 177 – 186 179

95% and basis weight was 115g/m2 [20, 21].


One series of indirect electrophotography samples was prepared so that the voltage of reverse rollers was
changed as follows: 0V, -50V, -125V, -200V and -250V. In the other series the change of the intermediate cylinder
voltage was: 500V, 550V, 600V, 650V and 700V.
During the experiment, only one stage in the printing process is varied, while all other parameters remained
constant defined by the initial calibration of the printing machine [22].
The method of alkaline chemical deinking flotation was used for recycling prints. In the previous article it was
described in details [23]. Laboratory handsheets are made with the use of standard sheet former Rapid- Köthen,
according to ISO 5269-2 [24]. On this handsheets using spectrophotometer Technidyne Color Touch 2, brightness
and effective residual ink concentration before and after flotation are measured [25].
According to the recycling process phase image analysis is made with the use of SpecScan® Apogee System
software in accordance with TAPPI standard method [26]. This system is utilizing scanner to digitize image.
Threshold value (100), white level (75) and black level (65) were chosen after comparing computer images to
handsheet.
The spectrophotometer X Rite DTP 41 and the application ColorShop X were used for calculating output results
such as: L*a*b*, c*, H*, x, y, Y. All values were measured three times and average values were used for further
*
analysis. The colour difference E2000 was calculated using the equation described by Luo and co- author and
Johnson and Green [27, 28]. The X-Rite DTP 41 device is suitable for measuring a large number of patches (in this
case the test chart with 378 colour patches). The measurements were used to create the ICC profiles using the
program MonacoProfiler Platinum v 4.8. From the generated ICC profiles space the colour gamut was formed and
gamut volumes were detected in the program Gamut Works v.1.0.

3. Results and discussion

In accordance with environmental sustainability and in order to optimize the recycling process of prints from
indirect electrophotography with liquid toner the results of investigating the effects of changes in printing conditions
on the characteristics of recycled fibers is presented. Changing of printing conditions, respecting of voltage
variations, comprises the third phase, in which is the development with reverse rollers. In addition, the study
includes the fourth stage in indirect electrophotography, which includes a first transfer of ink. In this transfer toner
particles from photoconductor surface are transmitted to the intermediate cylinder.
The impact of voltage changes in the described phases of an electrophotography printing with liquid toner to
specks number is shown in fig 1.
Increasing negative voltage of reverse roller in a range from 0V to - 250V leads to decrease in the number of
specks on handsheets made from the fibers before flotation as follows: N 0V/N -50V 4.4%, N 0V/N -125V 18,5%, N 0V/N
-200V 24,8% and N 0V/N -250V 34,1%. Total number of specks with flotation decreases from 5% -15% depending on
the voltage of reverse rollers. To lower negative voltage of revers rollers higher efficiency of removing specks with
flotation within the above-indicated values is associated.
With changing the voltage of intermediate cylinder in the range from 500V to 700V there were no major impacts
on the number of specks on handsheet. Depending on the voltage total number of specks ranges from 894 to 999,
which is no more than 25% more compared to the total number of specks obtained by varying the voltage of reverse
rollers. Separation of specks with flotation in the described experimental conditions is somewhat lower than those
obtained by varying the voltage of reverse roller and ranges from 3.8 to 5.6% depending on the voltage of the
intermediate cylinder.
180 Ivana Bolanca Mirkovic et al. / Procedia Engineering 100 (2015) 177 – 186

Fig. 1. (a) Total specks number on handsheet versus voltage of reverse rollers in printing; (b) total specks number on handsheet versus voltage of
intermediate cylinder in printing.

Area of specks on handsheets in relation to voltage of reverse rollers and intermediate cylinder is shown in Figure 2.

Fig. 2. (a) specks area on handsheets versus voltage of reverse roller; (b) specks area on handsheets versus voltage of intermediate cylinder.

The results show the opposite relationship between the areas of total specks (0V 29,71mm2, 50V 39,41mm2, -
125V 52,91mm2, -200V 65,09mm2, -250V 67,20mm2) in relation to the number of specks (0V 1216, -50V 1135, -
125 1005, -200V 893, -250V 829) on handsheets made from recycled fibers prints obtained by changing the voltage
of reverse rollers. By increasing the negative voltage of reverse roller in the printing specks area on handsheets
expands as follows: A0V/A -50V 24,2%, A 0V/A -125V 54,8%, A 0V/A -200V 60,7% and A 0V/A -250V 61,1%. Due to the
fact that increasing negative voltage of reverse rollers reduces the number of specks after pulping and increases
specks area, it actually means that the particles have a larger surface.
By increasing the voltage of intermediate cylinder in the printing the total specks area reduces as follows: A 500V/A
550V 7,3%, A 500V/A 600V 40,1%, A 500V/A 650V 48,3% and A 500V/A 700V 48,3%. Reduce of the total specks area for
Ivana Bolanca Mirkovic et al. / Procedia Engineering 100 (2015) 177 – 186 181

voltage of 500V of the intermediate cylinder is 51.1%, and then decreases as follows: V 550 45,9%, V600 23,6%, V650
1,6%, V700 6,6%.
More precise monitoring and interpretation of the deinking flotation mechanism in the described conditions is
possible with the use of image analysis and specks spot size from 0.001-0.006 mm2 to >=5mm2, which includes 26
spot sizes. The research results show that the increase in negative voltage of the reverse rollers formed larger flat
specks, sometimes larger than 5 mm2 (Table 1).

Table 1. Specks area in spot size >= 5mm2 after pulping and after flotation versus voltage of the reverse rollers.
Sample 0 (V) -50 (V) -125(V) -200(V) -250(V)

Total area of specks after pulping (mm2) 5,68 6,58 18,11 31,09 30,93
2
Total area of specks after flotation (mm ) 0 0 6,59 14,09 12,44

Described characteristic is not recognized when varying the voltage of the intermediate cylinder (Table 2).

Table 2. Distribution of large specks after pulping and after flotation versus the voltage of the intermediate cylinder.
Sample 500 (V) 550 (V) 600(V) 650(V) 700(V)
Total number of specks after pulping in 1 0 1 1 0
spot size >= 5mm2
Total number of specks after flotation in 0 0 0 0 0
spot size >= 5mm2
The biggest spot size (mm2) with specks 1,00-1,50 1,50 2,00 1,00-1,50 1,00-1,50 1,00-1,50
after flotation
Number of specks in the biggest spot size 1 1 1 1 1
with specks after flotation

Table 3. Distribution of specks after pulping and after flotation versus the voltage of the intermediate cylinder.
Sample 500 (V) 550 (V) 600(V) 650(V) 700(V)

Total number of specks after pulping in 79 78 89 56 74


spot size >=0.04mm2

Total number of specks after pulping in 838 875 833 837 859
spot size <0.04mm2

Total area of specks after pulping in spot 29,27 21,09 25,38 14,77 11,54
size >=0.04mm2

Total area of specks after pulping in spot 6,94 7,14 7,73 6,64 7,09
size <0.04mm2

Within the experimental conditions and the results displayed in Table 2 could be concluded that increasing the
voltage of the intermediate cylinder in the printing, is not particularly characteristic for specks number in spot size
>= 5mm2 on handsheet made from the fibers after pulping, as is the case with increasing the voltage of the reverse
rollers.
Presented results can be explained trough the principle of the electrophotography with liquid toner, as follows.
During the printing process the ElectroInk is transferred to the blanket that is heated to 1000C. This causes the toner
particle to melt and fuse together, forming hot adhesive liquid plastic. When the ink contacts relatively cool
substrate it solidifies, it sticks to it and is stripped off the blanket, leaving no residue behind.
Table 4 shows the brightness gain and effective residual ink concentration difference of the handsheets after
pulping and after flotation.
182 Ivana Bolanca Mirkovic et al. / Procedia Engineering 100 (2015) 177 – 186

Table 4. Brightness gain and difference of the effective residual ink concentration handshets after pulping and after flotation
in dependence of the type of the paper and the voltage of the reverse rollers in printing.
Voltage of the intermediate cylinder 500 (V) 550 (V) 600(V) 650(V) 700(V)
Brightness gain, uncoated paper 9,6 10,4 12,3 10,4 11,4
Brightness gain, coated paper 1.3 0,9 0,1 2,0 0,3
Δ ERIC, uncoated paper 43,1 41,4 49,4 48,5 54,6
Δ ERIC, coated paper 5,2 0,5 12,3 0,9 2,1
Voltage of reverse rollers 0(V) -50(V) -125(V) -200(V) -250(V)
Δ ERIC, coated paper 1,42 4,09 1,43 2,76 2,10

Results presented in Table 4 have good matching and confirm the results presented before, distribution of dirt
count and area, depending on the voltage of the intermediate cylinder and the type of printing substrate.
Flotation of prints on uncoated paper in relation to the voltage of the intermediate cylinder increases handsheet
brightness gain from 9.6 to 12.3, while on the print on both sides coated paper maximum values are 2.0. Difference
of the effective residual ink concentration decreases far more on handsheets obtained from floated fibres on
uncoated paper prints in relation to both sides coated paper prints.
One of the reasons for the poorer efficiency of the flotation is that ElectroInk heat fused into the paper, they tend
to form continuous film they are strongly across their area and when detached from paper fibres they were formed
the large plate-like structures.
The coating process assists in dispersing the fillers in the coating. In recycling process dispersants are surface
active and together with alkali can lead to acceptable ink detachment from the coated paper. These species can
hydrophilise ink containing agglomerates and hinder flotation efficiency as well as contribute to unwanted foam
stability.
As for sustainability implementation of quality is significant, Figure 3 shows a 3D gamut for prints depending on
the voltage of the reverse rollers and intermediate cylinder.

Fig. 3. (a) 3D gamut of the prints depending on the voltage of the reverse rollers; (b) 3D gamut of the prints depending on the voltage of the
intermediate cylinder.

Gamut volume at a reverse roller voltage of 0V is 551.702 CIE L*a*b* CCU, and at a voltage of -250V is 762.139
CIE L*a*b* CCU. By increasing the voltage from 0V to -125V a greater increase occurs in the gamut ΔV 125V-0V
178.472 CIE L*a*b* CCU, compared with ΔV-250V- -125 31,965 CIE L*a*b* CCU. Central part of the gamut body at
a voltage of 0V has the best reproduction for blue and green tones. Voltage of -250V will affect only the tones that
have high value at + b coordinate.
By changing the voltage of the intermediate cylinder largest 3D color gamut is obtained for a voltage of 700V (V 700
781,947 CIE L*a*b* CCU), and the smallest 3D gamut is at 500V (V500 744.224 CIE L*a*b* CCU).
Ivana Bolanca Mirkovic et al. / Procedia Engineering 100 (2015) 177 – 186 183

For an accurate analysis of the impact of printing conditions at the reproduction quality is necessary to measure
100% and 50% of raster fields of basic color of the subtractive and additive synthesis. The results of these
measurements in relation to the observed printing conditions are shown in Figures 4 and 5.

Fig. 4. (a) The dependence of the voltage reverse rollers on the CMYK color difference of the prints made by 100% and 50% of the raster tone
values; (b) The dependence of the reverse roller on the RGB color difference of the prints made by 100% and 50% of the raster tone values.

Prints obtained by variation of the voltage of reverse rollers with full tones have an average deviation of tints ΔE max
- ΔEmin 27,3 while 50% raster prints have ΔEmax - ΔEmin 33,4. The resulting deviations are as follows: ΔE100% red 32,1
(maximum value), ΔE100% cyan 19,7 (minimum value), and 50% raster prints: ΔE50% yellow 31,5 and ΔE 50% red 46,9. To
gain optimum print the -190V for yellow, -130V for magenta and 0V for cyan should be used.
184 Ivana Bolanca Mirkovic et al. / Procedia Engineering 100 (2015) 177 – 186

Fig. 5. (a) The dependence of the intermediate cylinder voltage on the CMYK color difference of the prints made by 100% and 50% of the raster
tone values; (b) The dependence of the intermediate cylinder voltage on the RGB color difference of the prints made by 100% and 50% of the
raster tone values.
By variation of the voltage of intermediate cylinder average deviation of tints ΔE max-ΔEmin 2,95 is achieved. The
smallest deviation of color is achieved for 100% raster cyan (ΔE100% cyan 0,3) and the highest at 100% raster yellow
(ΔE100% yellow 7,7). Raster prints 50% tone value have a slightly larger average color deviation (ΔE max-ΔEmin 3.5).
Between 50% raster colors magenta (ΔE50%magenta 3,9) and yellow (ΔE50% yellow 3,9) change the most. To gain
optimum print the voltage of intermediate cylinder of 600V for yellow, magenta, cyan, and blue and voltage of
650V for the red and green should be used.
Ivana Bolanca Mirkovic et al. / Procedia Engineering 100 (2015) 177 – 186 185

Conclusion

The basic stages in the indirect electrophotography process with liquid toner differently affect the print quality as
well as the deinking flotation, and characteristics of recycled fibers.
Based on the results it can be concluded that the change in the voltage of the reverse rollers (0V, -50V, -125V, -
200V and -250V) at the stage of developing more affect the recycling efficiency with respect to the voltage change
of the intermediate cylinder (500V, 550V, 600V, 650V and 700V) during transfer of ink from the photoconductor to
transfer media. Increasing of the positive voltage of the intermediate cylinder in the printing is not particularly
characteristic of speck number in spot size >= 5mm2 on handsheet made from the fibers after pulping, as is the case
with increasing of the negative voltage of reverse rollers. Brightness gain is higher when the print for recycling is
made on uncoated paper compared to coated, and is dependent on the voltage changes. Effective residual ink
concentration decreases far more on handsheets obtained from floated fibers on uncoated paper prints in relation to
both sides coated paper. Increasing the positive voltage of intermediate cylinder and increasing the negative charge
of reverse roller increases the color gamut volume. Guidelines for the size of the voltage in order to obtain optimal
prints are provided.
The further research will include the development of material flows, recycling, reuse, closed loop systems; therefore
the significant terms in the area of environmental sustainability.

Acknowledgements

The authors thank Ministry of Science, Education and Sport of the Republic of Croatia for support for this work.

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